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visual factory

Visual Process Management for Lean Manufacturing

Visual Factory supports lean manufacturing processes with a toolset that allows companies to create graphical and visual information flows across the production process. It is an Intranet based system for the creation, management and distribution of manufacturing documentation. Visual Factory provides the whole shop floor workforce with the information they need in a visual and interactive way. 

It is used by leading manufacturers including Caterpillar Inc., Volvo Construction Equipment, Racal Acoustics, TRW Aerospace, Yamanouchi Pharmaceuticals.  It offers a host of benefits, that can result in measurable savings. 

One customer has recently experienced significant saving including:

-Due to consistent use of the optimum process, a 5% increase in productivity – and this may increase to 10%.

-50% reduction in training time – as it is no longer necessary to spend so much time memorising the process and so training cost is halved.

-Reduced end of line rework due to more accurate identification of the correct components by use of barcode verification.

More Info:

       Visual Factory Features      complex manufacturing processes made simple

Work Instructions

-Clear visual instructions leave no room for confusion, mis-interpretation or ambiguity 

-Instructions are easier-to-read, easier-to-use, easier-to-follow

-Reduced time to prepare and maintain works instruction - quality and clarity is improved

-Accurate, up-to-date instructions are readily accessible for reference and can even be used in a complex assembly environment

Productivity

-Cuts new employee and cross training times dramatically – assemblers can be up-to-speed almost instantly

-Prevents the knock-on effects of worker absence (eg bottlenecks, delays) as it is easier to assign temporary staff or to re-allocate resources

-Right-first-time assembly with fewer errors or omissions reduces re-work time

-Quicker switch-over times between product lines.

Quality

-Ensure the latest release of build information is being used for production

-Lower inspection costs, as less testing and checking is required

-Instructions and best practice can be shared between facilities in different locations and with others in the supply chain -  suppliers, sub-contractors

-Reduce end of line re-working

-Reduce warranty claims

-Record technical data during assembly